U.S. patent application number 13/956681 was filed with the patent office on 2014-02-06 for compostable single-cup brew lid.
The applicant listed for this patent is Rob Pilez, Bill Reilly. Invention is credited to Rob Pilez, Bill Reilly.
Application Number | 20140037916 13/956681 |
Document ID | / |
Family ID | 50025762 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140037916 |
Kind Code |
A1 |
Reilly; Bill ; et
al. |
February 6, 2014 |
COMPOSTABLE SINGLE-CUP BREW LID
Abstract
A single-cup brew lid material comprises: a compostable printed
layer; and a compostable layer that is sealable to PLA single-cup
brew containers.
Inventors: |
Reilly; Bill; (Aurora,
CA) ; Pilez; Rob; (Aurora, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Reilly; Bill
Pilez; Rob |
Aurora
Aurora |
|
CA
CA |
|
|
Family ID: |
50025762 |
Appl. No.: |
13/956681 |
Filed: |
August 1, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61678828 |
Aug 2, 2012 |
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Current U.S.
Class: |
428/200 |
Current CPC
Class: |
B32B 3/10 20130101; B65D
43/14 20130101; Y02W 90/14 20150501; Y10T 428/24843 20150115; Y10T
428/24934 20150115; B65D 77/2024 20130101; Y02W 90/12 20150501;
B32B 23/08 20130101; B32B 2307/7242 20130101; B32B 29/002 20130101;
B32B 7/12 20130101; Y02W 90/10 20150501; Y10T 428/24802 20150115;
B32B 27/36 20130101; B32B 27/10 20130101; Y10T 428/31786 20150401;
B65D 65/466 20130101; B32B 2307/31 20130101; B65D 85/8043
20130101 |
Class at
Publication: |
428/200 |
International
Class: |
B32B 3/10 20060101
B32B003/10; B65D 43/14 20060101 B65D043/14; B32B 27/10 20060101
B32B027/10; B32B 7/12 20060101 B32B007/12; B32B 23/08 20060101
B32B023/08 |
Claims
1. A single-brew cup lid material comprising: a compostable printed
layer; and a compostable layer that is sealable to PLA single-brew
cups.
2. A material according to claim 1, wherein the compostable layer
that is sealable to PLA single-brew cups comprises a PLA-based film
and a compostable core layer, the compostable core layer being
disposed between the PLA-based film and the compostable printed
layer.
3. A material according to claim 2, wherein the compostable printed
layer is printed paper.
4. A material according to claim 2, wherein the compostable printed
layer is reverse-printed cellulose.
5. A material according to claim 2, wherein the PLA-based film is
metallized.
6. A material according to claim 2, wherein the compostable core
layer is an aliphatic copolyester.
7. A material according to claim 5, wherein the compostable core
layer is an aliphatic copolyester.
8. A material according to claim 6, wherein the compostable core
layer is a compostable extrudate.
9. A material according to claim 7, wherein the compostable core
layer is a compostable extrudate.
10. A material according to claim 6, wherein the compostable core
layer is a compostable film secured to the adjacent layers by
adhesive.
11. A material according to claim 7, wherein the compostable core
layer is a compostable film secured to the adjacent layers by
adhesive.
12. A material according to claim 11, wherein the PLA-based film is
about a 20 micron metallized PLA film; and the compostable core
layer is a 3 mil aliphatic copolyester film.
13. A material according to claim 12, wherein the printed layer is
a layer of printed about 21#/ream paper
14. A material according to claim 13, wherein the compostable core
layer is secured to the printed paper by about 1.5 gsm acrylic
adhesive and to the PLA-based film by about 1.0 gsm urethane
adhesive.
15. A material according to claim 2, having the following
properties: Ink adhesion: 100% ink adhesion using Scotch 610 tape
Heat and blister resistance: no visible blistering or ink pick-off
when sealed at 150.degree. C., 1 sec dwell time, 40 psi Interlayer
bond strength: >100 g/25 mm Elmendorf (propagated) tear
resistance: >150 g both machine direction and transverse
direction Heat seal strength, lid to cup: >1000 g/25 mm, lid
sealed against the rim of a PLA cup, 150.degree. C., 1 sec dwell
time, 40 psi Oxygen barrier: 0.4 cc/100 in2/24 hr Moisture barrier:
0.2 g/100 in2/24 hr
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of U.S. Provisional
Application 61/678,828 filed on Aug. 2, 2012.
FIELD OF THE INVENTION
[0002] The present invention relates to materials used for the
manufacture of single-cup brew lids.
BACKGROUND OF THE INVENTION
[0003] Single cup brew machines have become popular due to
convenience and quality of the beverage produced. The lids for
these cups often use foil and other non-compostable materials,
sealed to polystyrene or other non-compostable materials. As a
result, the lid and cup are typically discarded after use.
SUMMARY OF THE INVENTION
[0004] Forming one aspect of the invention is a single-brew cup lid
material comprising: a compostable printed layer; and a compostable
layer that is sealable to PLA single-brew cups.
[0005] According to another aspect of the invention, the
compostable layer that is sealable to PLA single-brew cups can
comprise a PLA-based film and a compostable core layer, the
compostable core layer being disposed between the PLA-based film
and the compostable printed layer.
[0006] According to another aspect of the invention, the
compostable printed layer can be printed paper.
[0007] According to another aspect of the invention, the
compostable printed layer can be reverse-printed cellulose.
[0008] According to another aspect of the invention, the PLA-based
film can be metallized.
[0009] According to another aspect of the invention, the
compostable core layer can be an aliphatic copolyester.
[0010] According to another aspect of the invention the compostable
core layer can be an compostable extrudate.
[0011] According to another aspect of the invention, the
compostable core layer can be a compostable film secured to the
adjacent layers by adhesive.
[0012] According to another aspect of the invention, the PLA-based
film can be about a 20 micron metallized PLA film; the compostable
core layer can be a 3 mil aliphatic copolyester film; and the
printed layer can be a layer of printed about 21#/ream paper
[0013] According to another aspect of the invention, the
compostable core layer can be secured to the printed paper by about
1.5 gsm acrylic adhesive and to the PLA-based film by about 1.0 gsm
urethane adhesive.
[0014] According to another aspect of the invention, the material
can have about the following properties:
[0015] Ink adhesion: 100% ink adhesion using Scotch 610 tape
[0016] Heat and blister resistance: no visible blistering or ink
pick-off when sealed at 150.degree. C., 1 sec dwell time, 40
psi
[0017] Interlayer bond strength: >100 g/25 mm
[0018] Elmendorf (propagated) tear resistance: >150 g both
machine direction and transverse direction
[0019] Heat seal strength, lid to cup: >1000 g/25 mm, lid sealed
against the rim of a PLA cup, 150.degree. C., 1 sec dwell time, 40
psi
[0020] Oxygen barrier: 0.4 cc/100 in2/24 hr
[0021] Moisture barrier: 0.2 g/100 in2/24 hr
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a stylized perspective view of a lamination
according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Reference is made to the exemplary embodiment illustrated in
FIG. 1, which will be seen to be a laminate material 20 comprising
six (6) layers:
[0024] 22 6 colour flexographic print
[0025] 24 21#/ream bleached kraft paper
[0026] 26 1.5 gsm acrylic adhesive
[0027] 28 3 mil BASF Ecoflex aliphatic copolyester film.
[0028] 30 1.0 gsm urethane adhesive
[0029] 32 80 ga (20 micron) metallized PLA film, supplied by
Celplast Metallized Products Limited
[0030] This material was tested, with results as shown below.
TABLE-US-00001 TABLE 1 Test Results Ink adhesion 100% ink adhesion
using Scotch 610 tape Heat and blister resistance Good (no visible
blistering or ink pick- off) when sealed at 150.degree. C., 1 sec
dwell time, 40 psi Interlayer bond strength >100 g/25 mm
Elmendorf (propagated) tear >150 g both machine direction and
resistance transverse direction Heat seal strength, lid to cup
>1000 g/25 mm, lid sealed against the rim of a PLA cup,
150.degree. C., 1 sec dwell time, 40 psi Oxygen barrier 0.4 cc/100
in.sup.2/24 hr Moisture barrier 0.2 g/100 in.sup.2/24 hr
[0031] In the description above, the following definitions
apply:
[0032] #/ream yield as lbs. per ream, where a ream is 3,000 square
feet
[0033] gsm yield as grams per square meter
[0034] mil unit of thickness, where 1 mil=0.001''
[0035] ga unit of thickness, where 100 ga=1 mil
[0036] micron unit of thickness, where 1,000,000 micron=1 meter,
and 25.4 micron=1 mil
[0037] psi lbs per square inch
[0038] The product was found to be sealable, compostable, and
useful in a variety of single cup brewing machines which use a
hollow needle to convey hot or cold water into the cup. The
structure was observed to create a gasket or self-sealing effect
when the hollow needle of the brewing equipment punctures the lid,
so that the hot brewing water under pressure cannot escape through
the puncture hole.
[0039] Other advantages associated with the structure include the
potential for reduced needle wear, as a result of the relatively
soft, non-metallic substrates that can be employed in the place of
the aluminum foil commonly used. As well, the gasket mechanism
allows use with a range of film types that can be used on a variety
of polymer resins materials used in the base cup. Further, by
replacing the aluminum foil commonly used in cup lids with a
non-metallic barrier layer such as a nano-composite barrier
coating, metal detectors can now be used as an added safety
feature.
[0040] Without intending to be bound by theory, the bonds, tear
resistance and heat seal integrity of the finished lamination
appear to be important to the functioning of the material in the
brewing machine. While no single test measures the gasket effect,
the propagated tear (Elmendorf) test has been found to be helpful
as it quantifies the resistance to deformation and breakage of the
soft gasket layer.
[0041] Whereas but a single exemplary embodiment is illustrated,
variations are possible.
[0042] For example, whereas in the exemplary embodiment, bleached
kraft paper is used, it will be understood that natural, bleached,
coloured or coated paper could be used, depending on the appearance
and print quality desired.
[0043] Further, cellophane can also be used in place of paper,
which would typically be reverse printed, to avoid direct exposure
of the print to the heat of the sealing operation and avoid ink
pick off or scuff.
[0044] Additionally, whereas the core layer in the exemplary
embodiment is an aliphatic copolyester film such as BASF Ecoflex,
other materials, other compostable materials such as Novamont Mater
Bi, BASF EcoVio or Indaco Biotope could also be used. The tensile
modulus and tear properties of this layer are critical in order to
have the softness and memory properties to allow the finished
lamination to puncture and then conform tightly to the shape of the
of the sharpened hollow needle while not tearing, splitting or
zippering, nor causing the lid to become separated from the sealing
flange of the cup.
[0045] Yet further, whereas in the exemplary embodiment, the inner
sealant layer is metalized PLA, other sealable, compostable films
such as Novamont Mater Bi, BASF EcoVio or Indaco Biotope could also
be used, depending on the cup or container resins used.
[0046] Moreover, whereas the exemplary embodiment involves the use
of an Ecoflex film core, secured by adhesive, the structure could
be produced by extrusion, in which case, that structure would
comprise four layers: (i) print; (ii) paper; (iii) extruded Ecoflex
resin; (iv) metallized PLA film.
[0047] In the exemplary embodiment, metallized PLA film is used;
this will normally be the case when a high barrier lamination is
required. If high barrier is not required, e.g. due to a barrier
overwrap being used to package the filled cups, then regular PLA or
other compostable films could and would normally be used.
[0048] Other alternate embodiments are shown in the table below
TABLE-US-00002 L AYERS Print substrate Adherent Core layer Adherent
Sealant layer Type 1 2 3 4 5 6 7 1 Print paper Adhesive BASF
EcoFlex film adhesive nano-coated PLA 2 print paper NA BASF EcoFlex
extrusion metallized PLA lamination 3 Print paper NA BASF EcoFlex
extrusion nano composite- lamination coated PLA 4 print paper
adhesive Novamont Mater Bi film adhesive metallized PLA 5 print
paper adhesive Indaco Biotrope film adhesive metallized PLA 6
cellophane print adhesive BASF EcoFlex film adhesive metallized PLA
7 cellophane print adhesive BASF EcoFlex film adhesive nano
composite- coated PLA 8 cellophane print BASF EcoFlex extrusion
metallized PLA lamination 9 cellophane print BASF EcoFlex extrusion
nano composite- lamination coated PLA 10 cellophane print adhesive
Novamont Mater Bi film adhesive metallized PLA 11 cellophane print
adhesive Indaco Biotrope film adhesive metallized PLA 12 print
Paper adhesive BASF EcoVio film (PLA-based) 13 print paper BASF
EcoFlex extrusion BASF EcoVio film lamination (PLA-based) 14 print
paper adhesive EcoFlex film heat seal coating
[0049] Types 12-14 are not metallized or nano-composite coated, and
therefore do not have the high oxygen barrier properties
appropriate for extended shelf life. Structures like these can be
used when the cups are packed separately into barrier packaging
overwrap, or when barrier is not required due to the shelf life
requirements of the product.
[0050] Yet further variations are possible. Accordingly, the
invention should be understood as limited only by the accompanying
claims, purposively construed.
* * * * *